AQ_F_0800081_20121220_CMPL_Fac-Ltr

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Perdue Farms Incorporated
P.O.Box 460
Lewiston Woodville, NC 27849
www.perdue.come
Office [phone]
December 20, 2012
Certified Mail Number: 7009 3410 0000 4514 1724
Lee A. Daniel, Chief
Technical Services Section
NDENR Division of Air Quality
1641 Mail Service Center
Raleigh, NC 27699-1641
Subject: Request for Information—Anhydrous Ammonia Release (11/30/2012)
Lewiston Processing Plant EPA ID: 1000 0010-9688
Lewiston, Bertie, North Carolina Fac. ID: 0800081
Dear Mr. Daniel:
Per the receipt of your letter dated December 5th 2012, we are forwarding this correspondence
as our formal response. Please find enclosed the PSM Incident Investigation and Reporting
Summary regarding the incident. We feel these documents adequately address the items
requested in your letter. If you should have any questions or concerns regarding this response
submittal, please do not hesitate to contact Reddick White (PSM Coordinator/252-348-4285) or
myself.
Sincerely,
Wayne Black
Director,AgriBusiness Environmental
Perdue Farms, LLC/Perdue AgriBusiness, LLC
252-348-4326
Enclosure: Verbal/Written Report Document
PSM Incident Investigation Document (
U
JAN ' 2 2013
A Family Commitment to Quality Since 1920—

INCIDENT INVESTIGATION
AmMONIA REFRIGERATION INCIDENT
Reference No.
113012
Facilih' information: Date of Incident: 11 / 30 / 2012
Name: PERDUE FARMS, INC. SIC Code:
Address: 3539 GOVERNORS ROAD
LEWISTON— WOODVILLE,NC 27849
Total Compressor Horsepower: 2,575 Normal Ammonia Inventory: 28,297
Incident Type(Check all that a h):
❑Near-Miss Liquid Spill Other:
®Vapor Release ❑ Fire/Explosion
Primary Source of Release(Check One):
❑Oil Drain Valve ❑ Pump ❑ Pressure Relief Valve
❑Compressor ❑ Pressure Vessel ❑ Automatic Control Valve
❑Condenser/Desuperheater ❑Piping ❑ Charging Connection/Source
❑Evaporator ❑ Manual Valve ®Other— LIQUID INECTION
FOR OIL COOLER.
Cause(s)Contributing to Release(Check an),that clpph):
❑ Human Factors ®Equipment Defect/Malfunction ❑Controls Failure
❑Design Shortcoming ❑Improper Installation ❑ Process Upset
❑Misapplied Equipment ❑ Mechanical Damage ❑Other Emergency
❑ Power Failure ❑Hydrostatic Expansion ❑ System Change
❑Corrosion ❑ Hydraulic Shock ❑ Maintenance Activity
❑ inadequate Maintenance ❑inadequate Administrative ❑ inadequate Labeling
❑ Earthquake Controls
Types of Changes Recommended to Prevent Recurrence(Check all that a 1):
Administrative Changes Engineering Changes
❑ Operating Procedures ❑ Design
❑Additional Training ®Equipment
❑Emergency Response Procedures ❑Piping
❑ Safe Wok-Practices ❑ Safety Equipment
❑ Labeling/ldentification ❑Mechanical Protection/Access
❑Maintenance Procedures ❑Controls
❑ Management of Change Procedures
Results of Incident(Provide Rec uestecl L1jo•nultiot):
Total Quantity of Ammonia Released: 36.433 pounds
Estimate of Property/Product Damages: -0-
Number of Serious Injuries: -0-
Number of Fatalities: -0-
i�THE FACILITY GROUP Rev. 0 Page 1
I
I

113012
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Location,Date, Time And Duration Of Incident:
LOCATION—COMPRESSOR ROOM #1
DATE— 11/30/2012
TIME—11:03 AINI
DURATION OF INCIDENT—APPROXIAMTELY 10 MINUTES
Circumstances Leading Uri To Incident:
.FAULTY SPORLAN SOLENOID VALVE ON MYCOM 250HP SCREW COMPRESSOR
ASSET#4916
Events and Actions As Incident Unfolded:
_TRAVIS WALLACE AND ALPHONSO GREEN WERE COMING DOWN THE STAIRS FROM ICE
MAKER ROOM OVER CR-I. AT ABOUT HALF WAY DOWN THE STAIRS, THE AMMONIA
ALARM IN CR-I STARTED GOING OFF IN CR-I. TRAVIS CHECKED ROOM LEVEL READINGS
AND THEY WERE AT 90. TRAVIS AND ALPHONSO ENTERED INTO CR-1 AND SAW AMMONIA
VAPORS IN CORNER OF CR-I. THEY WENT TO GO LOOK AT WHERE VAPORS WERE COMING
FROM AND HAD TO EXIT TO STAIR WAY TO RETRIEVE RESPIRATORS FROM RESPIRATOR
BOX IN CR-1 ENTRANCE.. TRAVIS CALLED JOHN HATHAWAY BY TWO WAY RADIO BEFORE
REENTERING CR-I TO ASSIST. THEY RENETERED AND LOCATED LEAK WAS COMING FROM
250HP MYCOM COMPRESSOR. THEY EXITED AND JOHN HATHAWAY WAS APPROACHING
CR-1 ENTRANCE. JOHN ASKED ALPHONSO GREEN TO NOTIFY JESSE WHITFIELD AS HE
DONNED HIS RESPIRATOR, JOHN AND TRAVIS ENTERED CR-1. JOHN ISOLATED DOWN
STREAM BY SHUTTING THE KING VALVE AND E-STOP BUTTON AND TRAVIS SHUT THE
LIQUID VALVE AT CR-I. DAVID WYNNE WAS WALKING BY THE ENTRANCE AND SAW JOIN
AND TRAVIS EXITING CR-I MAIN ENTRANCE. DAVID IMMEDIATELY NOTIFIED WAYNE
BLACK AT ]I:13AM. HE ALSO NOTIFIED UPPER PLANT MANAGEMENT. WAYNE BLACK,
ENVIRONMENTAL, CALLED NRC, NCDAQ, AND BERTIE EMERGENCY MANAGEMENT. (SEE
ATTACHED REPORT). CORPORATE SAFETY, DARYL SEE, WAS CALLED AT 12:20PM BY
REDDICK WHITE TO NOTIFY OF INCIDENT AND ACTIONS TAKEN.
Continue on additional pages if needed.
11 THE FAc UTY GROUP Rev.0 Page 2
i

113012
Investigation Teatm's Assessment of Root Ouse Of Incident:
SPORLAN VALVE FAILURE. PLUNGER TUBE BROKE LOOSE FROM THE SEAT.
Investigation Team's Assessment of Additional Contributing Causes:
-N/A—
Actions or Circumstances Which Either Helped to Minimize the
Effects of the Incident or That Could Have Minimized the Effects:
_HAVING TRAINED REFRIGERATION ASSOCIATES ON SITE AND IN THE SAME
BUILDING WHEN IT OCCURRED.
_IST SHIFT WAS NOT RUNNING THIS DAY, APPROXIMATELY 30 TO 40 PEOPLE ON SITE
AT THE TIME OF INCIDENT.
PROPER VENTILATION SYSTEM IN COMPRESSOR ROOMS
_ASSOCIATES PERFORMING DAILY ROUNDS TO INSPECT EQUIPMENT AND AREAS OF
THE PLANT.
Continue on additional pages if needed.
i, THE FACILITY COUP Rev.0 Page 3

Date and Time Team Commenced Investigation: //'.3�`�/� �p��5 �I /• ___.
Teem 51embership(List Team Leader First):
Nance Title Company Approval
age
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Location of Team's Working and Support Documents:
PSNI COORDINATORS OFFICE
Recommended Changes:
MCF Ref.No. Description of Change
-N/A- - VALVE WILL BE REPLACED / UPGRADED WITH REFRIGERATION
SPECIALTIES VALVE.
- ALL OTHER REMAINING OLDER SPORLAN SOLENOID VALVES
WILL BE REPLACED PER INCIDENT INVESTIGATION TEAM.
- WILL CALL GENERAL REFRIGERATION TO COME AND GIVE
QUOTES TO REPLACE REMAINING SPORLAN SOLENOID VALVES ON
SYSTEM.
Recommended Employee Reviews of Report:
00 THE FACILITY GROUP Rev. 0 Page 4

Copy Distribution Submitted By:
Signature Date
S3gl)awre Date
Received By:
Signature Date
DOC. He ID:
Signature Date
i�THE FACILITY CROUP Rev.0 Page 5

AMMONIA RELEASE CALCULATIONS
NOVEMBER 30, 2012
OPTION #2 IIAR Formula for Open System Releases (Used if release is a hole)
Value Round Hole Calcs
0.1875 Hole diameter (inches) 0.03515625
140 Gauge pressure (psig) 154.7
75 Line temperature (deg F) 75
10 Duration of Release (minutes) 10
AQ= (15.48) (Dsq) (Pa)
sgrt jr) + 459
AQ= 15.48 0.035156 154.70
sgrt 534
AQ= 84.1906
23.1084
AQ= 3.6433 Ibs/minute
Pounds= 36.4329
Total Pounds Released 36.433

R-1 need 18,975 20/hr
Fans 1>20,650 ctm
44 X 75= 3300 = Largest Fan: 21,81hr 2>16,495 ctm
Smallest Fan: 12,81hr 3>16,495 ctm
17',3" High, All Fans: 69,41hr 4>12,190 ctrn
OSHA: 3,300 etm Intake: 36.7 Sq. ft
56,925 Cubic Feet
Assumpations: 300 fpm intake
50 sq. ff intake area
Footnote: OSHA requires 1 cubic fUmin per sq, ft of solid floor
Natural'Ventilation
Cool 9.4(50) 117.25 (75.50)
9,762
Warm 9,4 (50) 119.25 (95-85)

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Co. GeneralReftiquation Company
P.O.Box 140 Delmar,Delaware 19940 [phone] FAX[phone]
E-mail:[e-mail]
December 10, 2012
Perdue Farms, Inc.
P.O. Box 460
Lewiston, NC 27849
Attn: Mr. John Hathaway
RE: Liquid Injection Replacement (CRI)
Bid#: 12-103S
Dear Mr. Hathaway:
General Refrigeration Company is pleased to offer the following price to
perform liquid injections repairs on a total of six (6) of your existing CRI compressors.
We will replace one (1) liquid injection valve station on the 250 HP Mycom, each of the
three (3) 125 Mycoms, the #1 Frick and the #3 Frick compressors in CRI, This will
also include replacing two (2) isolation valves, one (1)solenoid with strainer, one (1)
access valve, and pipe and fittings on each compressor. We will not replace the
thermostatic expansion valve, but shall replace its flanges, bolts and gaskets if
necessary.
Base Bid Price Includes:
(1) —Lot ammonia pipe and fittings
(1) —Lot consumables and testing materials
(1) —Lot ammonia shut-off and control valves
(1) —Lot primer and painting materials
(1) —Lot freight to the job site
(1) —Lot of travel and fiiel expenses
(1) —Lot labor (including premium time labor for installation)
Base Bid Price Excludes:
Any and all pump down of system
Any and all welding inspection services
Any and all taxes,permits, and bonds
Any and all electrical and tubing replacement
Any and all thermostatic expansion valve replacement
Total Base Bid Price:...............................................$ 16,892.0

Perdue Farms, Inc. —Lewiston, NC (Bid#12-1035) Page 2
- This proposal contains proprietary information of General Refrigeration
Company. Its contents may not be disclosed to other organizations or used for
other than the expressed purpose without the written request of General
Refrigeration Company.
By accepting this proposal, the owner and his representatives
acknowledge and accept the terms and conditions as stated on the enclosed
Acceptance of Proposal. The above price(s) may be withdrawn by General
Refrigeration Company if not accepted within thirty (30) days from the date of
this proposal.
Thank you for allowing General Refrigeration Company the opportunity
of quoting this project. I do hope that the information as presented here meets
with your approval; however, if you have any questions,please feel free to
contact me.
Sincerely,
GENERAL REFRIGERATION
COMPANY
Robert Ellison
Operations Manager
RBE/pdf

Perdue Farms, Inc. —Lewiston, NC (Bid#12-1035) Page 3
ACCEPTANCE OF PR OPOSA L
The price, specifications and conditions contained herein are satisfactory
and are hereby accepted. General Refrigeration Company is authorized to
do the above work as spec�fied.
Project: Liquid Injection Replacement (CRI)
Bid#: 12-103S
Date of Quote: December 10, 2012
Quoted Base Bid Price: ........$ 16,892,00
Date of Acceptance: Purchase Order Number:----
Signature: Title:
Taxable: YES or NO Sales Tax Exemption #.-
*Please provide a copy of your tax-exempt certificate ifyou are not taxable.
MD License#562227 MD HVA CR License#0009489
VA Class A Conti-actor's License#2 701-029806A NC Reft. Contractors License#3652
TERMS AND CONDITIONS: 20%down payment with placement of order,
major equipment will be invoiced two weeks prior to delivery with payment due
and required upon arrival atjobsite. Balance of project shall be invoiced with
monthly progress billings, net due upon receipt of'invoice. General
Refrigeration Company reserves the right to add to any invoice outstanding
more than 30 days a charge of.1%of the invoice amount. Invoices shall be paid
by funds deposited in a U.S. bank within the continental United States. Due to
the competitive nature of this proposal, no retainage may be deducted from any
invoice. Any and all liquidated damages and/or loss ofproduct and/or
production are excluded. The one-year warranty on new equipment (unless
stated otherwise) begins on date of startup or 18 months from date of shipment,
whichever comes first. This warranty is contingent upon the full payment of this
proposal. Should the full amount o/'this contract and/or any other outstanding
invoices not be received by General Refrigeration Company, and all warranties
shall be considered null and void. If no tax-exempt certificate is received by
General Refrigeration Company with the purchase order, the project shall be
considered taxable and the appropriate tax shall be added to the contract
amount. This price maybe withdrawn by us if not accepted within 30 days.
Upon delivery to thejobsite; the equipment shall be covered by owner's
insurance. General Refrigeration Company does not cover this equipment with
Builders Risk or any other insurance. The above terms and conditions shall be
binding and supersede any and all terms, conditions, and "boiler plate"ftom
any verbal or written purchase order.